Machine and method for making tufted rugs, carpets and the like



March 12, 1957 w. EBERSOLD MACHINE AND METHOD FOR MAKING TUFTED RUGS, CARPETS AND THE LIKE 3 Sheets-Sheet 1- Filed April 3, 1953 March 12, 1957 w. EBERSOLD 2,784,683 MACHINE, AND METHOD FOR MAKING TUF TED RUGS CARBETS AND LIKE '3 Sheets-Sheet 2' Filed April 5, 1953 March 12, 1957 r w. EBERSOLD ,WfiSB MACHINE AND METHOD FOR MAKING TUFTED RUGS, .CARPETS AND THE LIKE Filed April 3, 1953 3 Sheets-Sheet 3 United States Patent 7 r' 2,784,588 J Egg Patented Mar. 12, 1957 MACHINE AND METHOD FOR MAKING TUFTED RUGS, CARPET S AND THE LIKE William Ebersold, Norristown, Pa., assignor to James Lees and Sons Company, Bridgeport, Fa, a corporation of Pennsylvania Application April 3, 1953, Serial No. 346,740

17 Claims. (Cl. 11279) This invention relates to rugs, carpets or the like and more particularly to rugs, carpets or the like of the tufted type.

The principal object of the invention is to provide a rug of the tufted type wherein the side edges are in exact parallelism.

A further object of the invention is to provide a machine for making rugs of the tufted type which will produce rugs with side edges in exact parallelism.

A still further object of the invention is to devise a method for making rugsof the tufted type, having side edges in exact parallelism.

Fabricators of rugs of the tufted type have been confronted with the problem of obtaining a product having exactly parallel side edges. The fabric backing used in the manufacture of tufted type rugs frequently varies in width to an extent that the resulting product has undulating edges and steps have to be taken to compensate for the variations. The only method that has been available heretofore to compensate for such variations is to adjust the position or the backing roll in the tufting machine. This method has proved unsatisfactory for the reason that a large quantity of backing was often fed into the machine between the time that the irregularity was noticed and the time the position of the backing roll could be adjusted. This invention contemplates the elimination of the necessity for adjusting the position of the backing roll in a manner hereinafter described.

A more particular object of the invention is to provide means for folding the edge portions of the backing in such a manner that the edges of the rug are parallel and that the variations in the width of the backing appear in the concealed hems rather than in the useful portion of the rug.

These and other objects of the invention and the various features and details of the construction and operation thereof are more fully set forth hereinafter with reference to the accompanying drawings, in which:

Fig. l is a vertical elevation view, partly in section, of the machine of the present invention;

Fig. 2 is an enlarged fragmentary view similar to Fig. l and showing the details of the tufting means;

Fig. 3 is a view taken substantially on line 33 of Fig. 1;

Fig. 4 is a view taken substantially on line 4-4 of Fig. 1;

Fig. 5 is an enlarged vertical elevational view, partly in section, of the rug of the present invention taken substantially on line 5--5 of Fig. 4;

Fig. 6 is a view taken substantially on line 66 of Fig. 4;

Fig. 7 is a view taken substantially on line 77 of Fig. 4;

Fig. 8 is a view in perspective on the width adjusting means disclosed in Figs. 4 and 6, and

Fig. 9 is a view in perspective of the folding horn disclosed in Figs. 4 and 7.

With reference to the drawings the machine for making rugs of the tufted type therein illustrated comprises the conventional tufting machine generally indicated by reference numeral 1, having a plurality of needles 2 depending from a needle bar 3 and being provided with a plurality of hold-down bars 4 to prevent rufliing of the backing fabric in front of the needle bar. The usual letout rollers 5 are provided to effect steady feed of the yarn 6 to the needles 2. The angle of yarn feed is controlled by yarn guides 7. As seen clearly in Figs. 1 and 2 the hold-down bars are mounted on an elongated angle member 8 which in turn is secured to the housing of the tufting machine by a plurality of brackets 9. The tufting machine is suitably mounted on a base 10. Fig. 2 discloses the details of the tufting operation and when this figure is viewed with Fig. 1 it will be apparent that loopers 12 are mounted on rocker arms 13 which in turn are mounted on a horizontal shaft 14 to effect rocking motion of said loopers. A knife 15 is mounted on an eccentric shaft 16, the knife cooperating with the loopers to bring about tufting of the rug as will be apparent as the description proceeds.

A roll of backing fabric 17 having a core i8 is mounted on an elongated shaft 19 the ends of which rest in cradles 22 permitting horizontal adjustment of the roll with respect to the cradles. An adjusting bar, generally indicated by reference numeral 23, is pivoted to angle'plate Z4 which is firmly secured to the floor. This adjusting bar comprises two sections 25 and 26, the former being secured at one end to'the angle plate and having at the other end a suitable handle 27. The section 26 is arcuate in construction and is secured to a portion of the section 25 which is correspondingly arcuate forming a split ring, the walls of which being provided with elongated slots for the reception of pins 28 which are firmly secured to ring 30 which engages collars 31 when the handle 27 is actuated. It will be apparent that the shaft 19 may be moved horizontally in either direction merely by moving the handle of the adjusting bar 23 in either direction as desired. The adjusting bar 23 is used only to effect major adjustment of the roll 17 with respect to the tufting machine, as when a new roll is installed. The present invention eliminates the need for such adjustments while the tufting machine is in operation.

The direction of feed of the backing fabric is controlled by idler rollers 29 so that as the fabric is fed towards the tufting machine, the side edges of the fabric engage folding horns 32 which 'are adjustably mounted on the base of the tufting machine. The folding horns fold the edges of the fabric so that the effective width of the rug at this point is less than that desired in the finished product. The fabric then engages spread rollers 33 which eliminate any wrinkles in the fabric that may have resulted from the folding operation. Pin roller 34, which receives power from 'a suitable source, then positively engages the fabric and moves it further towards the tufting needles. An additional power actuated pin roller 49 is provided to assure that the backing fabric is taut at the point of tufting. Further idler rollers 41 are positioned with respect to the pin roller 40 so that maximum contact between the pin roller and the backing fabric is efiiecte'd. interposed between pin roller 34 and the tufting needles is guide means 35 mounted on the base of the tufting machine for a purpose that will be apparent. As clearly shown in Figs. 4 and 8 the guide means comprises an elongated bar 45 having a plurality of elongated slots 35 therein for the reception of fastening elements 37. The bar has at one end a downwardly off-set portion 38 which is secured to guide element 39. A cammed surface 42 on the guide element increases the width of the backing fabric as desired. The guide means further has a spreader bar 43 which extends substantially normally to the bar 4-5 of the guide means when the guide meansis in operative relation with respect to the fabric backing. This spreader bar cooperates with the guide element to effect adjustment of theefiective width of the fabric backing. As shown in Fig. 8 the spreader bar extends further outwardly than does the guide element and engages the under side of each hem so that the hems of the fabric backing will be taut between these two elements and so that the effective width of the finished product is justed as predetermined and any variations in width of the fabric backing are taken up in the hems.

It will be understood that the tufts are formed by the successive piercing of the backing fabric by the yarn bearing needles. The loops thus formed are engaged by the loopers 12 which have knife portions at the rear of the under edges. As the looper rocks downwardly the knife 15 which is also mounted on a rocking shaft moves upwardly to effect severance .of the yarn at the bottom of the loops. The hems as well as thebody portion of the backing fabric are tufted so that additional stitching of the hems is not necessary. A latex coating 44 is then applied to the entire under side of the rug thus formed to secure the tufts in place and to eliminate slippage of the rug when used.

While a certain embodiment of the present invention has been illustrated and described herein, it is not intended to limit the invention to such a disclosure, and changes and modifications may be made therein and thereto within the scope of the following claims.

Iclaim:

1. A machine for making rugs, carpets and the like of the tufted type comprising means operable upon movement of fabric backing which is fed from a roll to fold the edges of said fabric backing so that the body portion of said backing is of a predetermined width and so that hems are formed thereby, spreader rollers operable upon movement of said fabric backing to spread said fabric backing, power actuated pin rollers to effect positive movement of said fabric backing, means to increase the width of the body portion of said backing to a predetermined greater width, spreader bars to increase the width of said body portion to even greater width, means operable upon further movement of said backing to smooth the entire width of said backing, a plurality of needles operable to tuft the entire width of said backing including said hems and a power actuated pin roller positioned behind said needles longitudinally to stretch said backing for-the tufting operation.

2. A machine for making rugs, carpets and the like of the tufted type comprising a 'U-shaped means operable upon movement of fabric'backing which is fed from a roll to fold the edges of said fabric backing so that the body portion of said backing is of a predetermined width and so that hems are formed thereby, spreader rollers operable upon movement of said fabric backing to spread said fabric backing, power actuated pin rollers to effect positive movement of said fabric backing, guide means mounted on the base of said machine and adapted to increase the width of said body portion of said backing to a predetermined greater width, spreader bars to engage said hems further to increase .the width of said body portion, hold-down means to smooth the entire width of said backing, a plurality of needlesoperable to tuft the entire width of said backing including said hems and apower actuated pin roller positioned behind said needles longitudinally to stretch said backing for the tufting operation.

3. A machine for making rugs, carpets and the like of the tufted type comprising a 'U-shaped folding horn operable upon movement of fabric backing which is fed from a roll to fold the edges of said fabric backing so that the body portion of said backing is of a predetermined width and so that hems are formed thereby, spreader rollers operable upon movement of said fabric backing t spread said fabric hacking, power actuated pin rollers plurality of hold-down bars adapted to smooth the entire width of said backing, a plurality of needles operable to tuft the entire width of said backingincluding saidjhems and a power actuated pin roller positioned ,behind said needles longitudinally to stretch said backing for the tufting operation.

4. A machine for making rugs, carpets and the like of the tufted type comprising a tufting machine mounted on a base, said tufting machine having a pluralityof'needles, let-out rollers operable upon movement of said needles to feed yarn to said needles, yarn guides adapted to control the direction of said yarn, a plurality of rollers adapted to feed fabric backing from a roll, means -operable upon movement of said fabric backing to fold the edges thereof so that the body portion of the said backing is of a predetermined width and so that hems are formed thereby, spreader rollers operable upon movement of said fabric backing to stretch said fabric backing, power actuated pin rollers to effect positive movement of said fabric backing, means to increase the width of the body portion of said backing to a predetermined greater width, means further to increase the width of said body portion, means operable upon further movement of said backing to smooth the entire width of said backing, a plurality of rockably mounted loopers operable upon downward movement of said needles to engage a loop of yarn thus formed and to sever said. yarn, a plurality of rockably mounted knives adapted to cooperate with said loopers to effect severance of said yarn, said needles being adapted to tuft the entire Width of said backing including said hems.

5. A machine for making rugs, carpets and the like of the tufted-type comprising a tufting machine mounted on a base, said tufting machine having a plurality of needles, let-out rollers operable upon movement of said needles to feed yarn to said needles, yarn guides adapted to control the direction of said yarn, a plurality of rollers adapted to feed fabric backing from a roll, means operable upon movement of said fabric backing to fold the edges thereof so that the body portion of the said backing is of apredetermined width and so that hems are formed thereby, a U-shaped means operable upon movement of: fabric backing which is fed from a roll to fold the edges of said fabric backing so that the body portion of said backing is of a predetermined width and so that hems are formed thereby, spreader rollers operable upon movement of said fabric backing to spread said fabric backlug, power actuated pin rollers to effect positive movement of said fabric backing, guide means mounted on the base of said machine and adapted to increase the body portion of said backing to a predetermined greater width, means further to increase the Width of said body portion, holddown means to smooth the entire width of said backing, a plurality of rockably mounted loopers operable upon downward movement of said needles to engage a loop of yarn thus formed and to sever said yarn, a plurality of rockably mounted knives adapted to cooperate with .said loopers to effect severance of said yarn, said needles being adapted to tuft the entire width of said backing including said hems.

6. A machine for making rugs, carpets and the like of the tufted type comprising a tufting machine mounted on a base, said tufting machine having a plurality of needles, let-out rollers operable upon movement of said needles to feed yarn to said needles, yarn guides adapted to control the direction of said yarn, a plurality of rollers adapted to feed fabric backing from a roll, means operable upon movement of said fabric backing to fold the edges thereof so that the body portion of the said backing is of a predetermined width and so that hems are formed thereby, spreader rollers operable upon movement of said fabric backing to spread said fabric backing, power actuated pin rollers to effect positive movement of said fabric backing, adjustable guide means to increase the width of the body portion of said backing to a predetermined greater Width, means integral with said guide means to engage said hems further to increase the Width of said body portion, a plurality of hold-down bars adapted to smooth the entire width of said backing, a plurality of rockably mounted loopers operable upon downward movement of said needies to engage a loop of yarn thus formed and to sever said yarn, a plurality of r'ockably mounted knives adapted to cooperate with said loopers to eifect severance of said yarn, said needles being adapted to tuft the entire width of said backing including said hems.

7. In a machine for making tufted rugs, carpets and the like in which fabric backing is fed into said machine from a roll, adjustable folding means comprising a U- shaped horn operable upon movement of said backing to fold the edges thereof forming hems along the side edges thereof, adjustable T-shaped guide means adapted to engage the under side of said hems and to increase the width of the body portion of said backing to a predetermined size.

8. A guide means adapted to decrease the width of fabric hems comprising a bar having elongated slots therein to receive fastening elements, a guide element secured to said bar and offset therefrom, said guide element having a cammed surface operable upon movement of said fabric to decrease the width of said hems to predetermined size, a spreader arm integral with said guide element and extending oppositely with respect to said bar and being adapted to engage the inside of said hems, and further to decrease the Width of said hems.

9. A machine for making rugs, carpets and the like comprising means adapted to feed backing from a roll, means operable upon movement of said fabric to fold the edges thereof so that the effective width thereof is less than desired in the finished product and so that hems are formed along each edge, means operable upon further movement of said fabric to press against the rounded interior surfaces of the folded portions so as to increase the width of the unfolded portion to a predetermined size, the variations in the width of said backing being taken up in said hems, means operable upon further movement of said backing further to increase the width of said body portion and means to tuft the entire width of the rug including said hems.

10. A machine for making rugs, carpets and the like comprising means adapted to feed backing from a roll, means operable upon movement of said fabric to fold the edges thereof so that the rug is of predetermined size and so that hems are formed, variations in the width of said backing being taken up in said hems, means operable upon movement of said backing to tuft the entire width of the rug including said hems.

11. A method of making tufted pile fabric comprising the steps of continuously advancing a backing in the direction of its length, continnoasly turning in along parallel lines the lateral margins of the backing against a face of the backing during its advance to provide a double ply marginal hem portion along each side edge of the backing, and continuously passing a series of pile yarns at intervals through the backing during its advance to form pile projections, the outermost pile yarns of said series projecting through said marginal hem portions.

12. A machine for making tufted pile fabrics comprising means to pass a Web of backing fabric longitudinally thereof from a roll, means including a reversely folded plate mounted at each side of the machine to engage the opposite side edges of said backing fabric Web and operable upon feed of said backing fabric web to fold the same inwardly and form marginal hem having parallel fold lines constituting the outermost edges of the backing fabric and defining the Width thereof, and needle means also operable upon movement of said backing fabric to project a series of pile yarns through said hems and said backing across the full width of the latter to form pile elements across the full width of said backing including said hems to secure the hems in place.

13. A machine according to claim 12 wherein said reversely folded plate comprises a U-shaped horn.

14. Apparatus according to claim 13 including means mounting said U-shaped horn for lateral adjustment to regulate the width of said backing between said marginal hems.

15. A method according to claim 11 including the step of laterally tensioning the backing prior to passing the pile yarns therethrough.

16. The method according to claim 15 wherein said lateral tensioning is performed by pressing against the rounded interior surfaces of the hem portions at the fold line thereof.

17. The method according to claim 11 wherein the backing is turned in along parallel lines spaced apart a distance less than the Width desired in the finished product and including the step of thereafter increasing the width of the unfolded portion to a predetermined uniform size desired in the finished product.

References Cited in the file of this patent UNITED STATES PATENTS 396,415 Morrison Jan. 22, 1889 1,026,547 Adair et a1 May 14, 1912 1,825,635 Myers Sept. 29, 1931 2,020,892 Kadlec Nov. 12, 1935 2,099,626 Robinson Nov. 16, 1937 2,335,487 Cobble et a1. Nov. 30, 1943 2,360,398 Case Oct. 17, 1944 2,411,268 Hamrick Nov. 19, 1946 2,534,686 Strauss et al Dec. 19, 1950 2,564,631 Veitch Aug. 14, 1951 2,584,493 Olsen Feb. 5, 1952 

